Wall and ceiling construction



May 21, 1935.v a. R. WALPER WALL AND CEILING CONSTRUCTION Filed May 25, 1929 4 Sheets-Sheet l ATTORNEYS May 21, 1935. 4 G. R. WALPER I 2,002,303

WALL AND CEILING CONSTRUCTION Filed May 25, 1929 4 Sheets-Sheet 2 ,cyfl 15 163 16 1 16 ATTORNEY May 21, 1935. G. R. WA LPER WALL AND CEILING CONSTRUCTION 4 Sheets-Shef. 3

Filed May 25, 1929 y I G. R. WALPER 2,002,303

WALL AND CEILING CONSTRUCTION Filed May 25, 1929 4 Sheets-Sheet 4 INVENTOR ATTORNEYS "UNITED STATES PATENT OFFICE Gordon R. Walper, Detroit, Mich., assignor to Curry Ora Walper, Royal 0ak,l\Iich.

Application May 25, 1929, Serial No. 365,951

'7 Claims." (01. 72-115) The invention relates to a metho for securing plaster boards or the like to wall and ceiling structures and has as its objects to sim-' d and means plify,.render more eflicient and improve gener- 5 ally methods and means of this character.

In wall and ceiling constructions of the char acter to which this invention particularly pertains it is customary to provide channel members adapted to receive therparallel edges of the plaster boards .or the like, to reinforce and supportthe same with respect. to the studding or other frame members.

In wall or ceiling structures, wherein the channel members are secured to wooden frame members, attachment is prefer- 1 ably made by means of driven headedmembers,

and in structures wherein steel channel-shaped frame members or studding istemployed, the

channel members are customarily secured in place by metallic attaching clips.

and one which will be strong, durab wise commercially satisfactory.

1e and other- To this end one of the important objects of this invention is to provide an improved construction of double channel-shaped members which may be quickly and economically large quantities, either from a single strip of construction metal bent to produce the desired produced in or from two strips of metal which are first suitably shaped and then subsequently united to produce the desired double channel-shaped member.

Still another object of the invention is to provide, in connection with any of the forms of channel members herein illustrated stituting and providing a plasterigauge whereby a minimum thickness for the plaster coat,

which is subsequently applied to the wall or ceiling structure, is established.

The invention further contemplates and has as its objects improvements in the means for attaching the double channel members to both wooden and. metallic studding or frame mem bers tothe means for insuring an adequate union or bond between the plaster coat and the double channel member; and to the means ing and otherwise strengthening t for reinforche attaching elements employed in connection with. the metallic frame members. I 1

In addition, the invention contem plates 2. con- ,pre-marked plaster boards or the like, whereupon struction wherein a solid sectionv of plaster is made possible at the joints supported by the double channel members so that expansion and contraction at these points is made uniform and the possibility of surface cracking eliminated.

Another important object of the invention is to provide a wall and ceiling construction of the described character wherein, when wooden frame members are employed, the plaster board supporting means cooperate therewith to rigidly tie together the spaced frame members, whereby a strong, rigid and commercially practicable wall or ceiling is produced.

,The invention further contemplates the use of plication of thepresent invention;

Figure 2 is an enlarged sectional view taken substantially in the plane indicated by line 2.-'-2 in Figure 1;

Figures 3, 4 and 5 are views showing themanner in which one of the sections of one offthe forms of channel member is developed;

Figure 6 is a view showing semi-diagrammatically the manner in which the plaster gauge pro jections can be formed in the channel part illustrated in Figures 3, 4 and 5;

Figure 7 is a fragmentary perspective view of this form of channel member; j

Figure 8 is a fragmentary sectional View showing semi-diagrammatically one means by which the sections of channel member, illustrated in Figure 7, may be united;

Figure 9 is a central vertical sectional view through a portion of a channel member united in accordance with the means illustrated in Figure 9;

Figure 10 is an edge view of the blank from which another form of double channel member may be developed;

Figure 11 is a sectional view through the form of channel member developed from the single strip of metal illustrated in Figure 10;

Figure 12 is a view somewhat similar to Figure 11 of a slightly modified form of channel construction developed from a single strip of metal; 5

Figure 13 is a fragmentary perspective view of a channel member showing a modified form of plaster gauge means associated therewith;

Figure 14 is a similar view showing another form of plaster gauge;

Figure 15 is asimilar view showing still another form of plaster gauge;

Figure 16 is a transverse sectional view through a double channel member showing plaster anchorage means associated with the bases ofthe channels;

Figure 17 is a fragmentary elevational view of the structure illustrated in Figure 16;

Figure 13 is a view similar to Figure 16 of another modified form of construction;

Figure 19 is an elevational view of the structure illustrated in Figure 18; V

Figure 20 is a sectional view through a wall construction showing the bases of the channel member provided with another form of plaster anchorage means;

Figures 21 and 22 are respectively transverse sectional and elevational views of a double channel member formed of two separate channels united in the manner illustrated semi-diagrammatically in Figure 8;

Figure 23 is a fragmentary sectional view througha wall constructionillustrating a modified means for securing the channel member to the studding;

Figure 24 is a similar view but modified to the extent that the channel securing means constitutes the plaster gauge;

Figure 25' is a fragmentary perspective view showing the double channel members attached to a steel frame member;

Figure 26 is a perspective View of one of the attaching clips employed;

Figure 27 is a view illustrating more clearly the manner in which the attaching clip illustrated in Figures 25 and 26 is connected to the frame member;

Figure 28 is a fragmentary perspective view showing modified form of an attaching clip associated with the frame member;

Figure 29 is a similar view showing still another modifiedforn'iv of attaching clip;

Figure 30 is a similar view showing another modified form of attaching clip;

Figure 31 is a sectional View through a clip taken substantially on a plane indicated by the line Iii-3i in Figure 29;

Figure 32 is a fragmentary vertical sectional view of a ceiling construction showing in general the application of the present invention when metal frame members are employed;

Figures 33 and 34 are perspective views of modified forms of attaching clips;

Figure 35 is a View of still another modified form of attaching clip;

Figure 36 is a sectional view through a different form of frame member showing the clip and channel member secured thereto;

Figure 37 is a plan view of a pre-marked plaster board or the like. 7

Figures 38 and 39 are respectively sectional and elevational views of a modified form of means for securing the two parts of the double channel member together.

Figures i0 and 41 illustrate semi-diagrammatically another method and means for securing together the two parts of the double channel member; and

Figure 42 is an elevational view, with certain parts broken away, of a wall construction illustrating the manner in which the plaster board supporting means act to reinforce the frame members. I

Referring now more particularly to the drawings wherein like reference characters indicate corresponding parts throughout the several views, and more particularly to Figure 1, it will be noted that there is illustrated a vertical section through a wall and ceiling construction in which the reference character [0 indicates the horizontal ceiling frame members and l I the vertical wall frame members. In Figure 1 these frame members are of wood, and as a consequence the manner in which a wall constructed in accordance with the present invention is attached to wooden frame members will be first described.

As seen from Figure 2, the invention contemplates the attachment of plaster boards or the like i2 to the frame members IE! or H by means ofdouble channel members indicated generally by the reference character 53 and shown more particularly in perspective in Figure 7. These channel members are substantially H-shaped in cross section and present a pair of opposed channels, each of which is adapted to receive, reinforce and support the adjacent parallel edge of a plaster board 52 and to be secured to the respective frame member at the points of intersection therewith by means of driven headed elements M.

The invention contemplates means whereby these channel members may be economically produced in large quantities and to this end several forms of channel member and'several methods of constructing the same are herein illustrated.

As will be apparent from an examination of Figure 7, one form of channel member comprises two parts 15 and I6, preformed and united in the manner to be later referred to. The channel member is formed from strips of sheet metal and the section It is bent tothe desired cross sectional contour in the manner most clearly suggested in Figures 3, 4 and 5.

In Figure 3 it will be noted that the flat strip [6a is bent along the lines I61) to the cross sectional contour illustrated in Figure l, and then further bent along the lines I wherein the bases I6e of the completed channel are provided, together with an intermediate portion 16 for attachment to the other section l5 of the channel.

The two sections [5 and E6 of the channel member, illustrated in Figure '7, may be united, as for instance, by spot welding, as indicated at H, or they may be united by cutting tongues from the abutting portions of the sections and i6 and bending these tongues back upon the adjacent portion as illustrated in Figures 8 and 9. In Figure 8 there is semi-diagrammatically illustrated a tool 18 having a portion I9 which may be run through the channel formed by the bases Ifie to the double channel member to cut therefrom tongues 20, which are subsequently bent back upon the abutting portion of the members 15 and I6, as illustrated in Figure 9. This not only secures the members l5 and I6 together to produce the form of channel illustrated in Figure 7, but provides apertures 2| permitting the passage therethrough of the driven headed elements I4, employed for securing the channel members to the frame members. The formation of the tongues 20 may obviously be accomplished by a stamping operation.

The outer flanges of the channel members are provided with plaster gauge means for indicating the minimum thickness of the plaster coat, which means in the present form are shown as pressed out loops or extensions 22. These pressed out loops may be conveniently formed by producing a pair of spaced parallel short slits and then displacing the metal therebetween outwardly out of the general plane of the flanges in which they are formed. The manner in which this might be economically accomplished is illustrated semi-diagrammatically in Figure 6, in which cooperating forming members 23 and 24 are provided. This operation mayalso be accomplished by a stamping operation. l

, By forming the channel illustrated in Figure 7 in two sections the plaster gauge projections 22 can conveniently be formed inthe section l6 before this section is assembled with the section l5, thus making the production of this form of channel member commercially acceptable.

In Figures 10 and 11 there is illustrated an improved form of channel member, formed from a single strip of metal. In constructing this form of channel member the plaster gauge projections 22a would, in order to facilitate the manufacture, be formed in the blank 25 before the same is folded. The blank is folded along the lines 25a, 25b and 25c, to produce respectively the portions 26, 21, 28 and 29 of the completed channel member illustrated in Figure 11. It will be noted that the portions 25 and 26 are bent tightly back upon themselves so as to produce a double wall thickness throughout the greater portion of that side of the channel member. However, the medial line of the channel, which must be perforated when the headed element I4 is driven in place, is of but a single thickness, so that it is unnecessary to perforate these channels as the metal is sumciently'thin, so that the headed element may be driven therethrough and into the frame member In. This is particularly true because the flange 26 of the double channel member is supported directly against the frame member Ill and cannot spring or give whenthe headed member I4 is driven therethrough. i

It is important to note that in all of the forms of channels constituting a part of this invention the head Ma of the driven securing element 14 spans the space between the bases of the channels and engages the side flanges thereof, (see, for instance, Figures 2 and 11) whereby the channel member is rigidly secured in place.

In Figure 12 there is illustrated a modified form of channel member 20; also developed from a single strip of metal, but in this form of construction the side flanges 3| are extended beyond the longitudinal edges of the side flanges 32. In this form of construction the plaster gauge loops or projections 2221 may be formed in the channel member after the channel member has been produced, and in Figure 12 there is indicated in dotted lines forming dies or tools 23a and 24a, similar to the forming diesillustrated in Figure 6.

While heretofore the plaster gauge means has been described and illustrated as consisting of loops pressed out from the general plane of the flanges in which they are formed, it will be noted from an examination of Figures 13, 14 and 15 that various other forms of plaster gauge means may be employed. In Figure 13 the double channel member 13 has the flanges at one side thereof formed with longitudinally extending ribs 33 which project outwardly beyond. the general plane of these flanges so as to provide a gauge for insuring a minimum thickness of plaster. In

Figure 14 the edges of the flanges of the double channel member are fluted or undulated as indicated at 34, thus producing plaster gauge pro-' jections or extensions. In Figure 15 the flanges are perforated as indicated at to produce outwardly extending tubular bosses 36.

It will be understood that when the plaster coat is applied to wall or ceiling structures employingdouble channel members of any of the forms herein illustrated and described, the plaster enters and fills the channel 31 formed by the bases lie of the opposed channels. It is oft times desirable to provide means acting as an anchorage for the section of plaster which enters and fills this channel 31, and in Figures 16 to 20 inclusive, several forms of plaster anchorage means are illustrated. For instance, in Figures 16 and 17 the bases Hie have loops 38 similar to the loops 22, pressed outwardly therefrom,

it being apparent from Figure 17 that these loops are staggered with reference to one another, so that the loops of one of the bases I62 project into the spaces between the loops or" the other base We. Thus when plaster enters the channel 31 it will extend not only in the spaces under the loops 38, but also in the tortuous space between this loop to thus provide an adequate anchor for thissection of plaster.

In the modification shown in Figures 18 and 19 the plaster anchorage means is also employed as a reinforcement for the channel member, and to this end portions or enlargements 39 are struck out from the bases I66 of the channels, these struck-out portions being arranged in opposed relation and abutting and they may be welded or otherwise secured together if desired, so as to strengthen the bases of the channels of the double channel member at this point. Obviously the plaster which enters the channel 3'! will fill in around and behind this abutting projection 39 so that this section of plaster is also adequately anchored.

In Figure 20 the anchorage of the plaster coat is accomplished by inclining the bases Hie of the channels to provide a tapered or wedgeshaped channel 4!, which is smaller at its open side, so that when the plaster enters and fills the wedge-shaped channel 4i and subsequently sets or hardens, the loosening or removing of this section of plaster from within the channel will be prevented by reason of this wedge-shape. In Figures 21 and 22 there is illustrated another modified form of channel member which con sists of a pair of separate channels 42 arranged in back-to-back relation and secured together, as for instance, by means of return bent tongues 43 similar to the tongues 20 in Figures 8 and 9.

Obviously the channel members may be secured to the studding or frame members in other ways than by driving the headed elements through the medial line or center thereof, and. in Figure 23 the channel member [3 shown as secured in place by driven headed elements 44, driven into the studding H1 at both sides of the channel member, with the heads 4w thereof overlapping the adjacent edges of the channel member. Obviously these driven elements 44 are also passed through the plaster boards I2.

In Figure 24 a construction is shown wherein the driven headed element which is employed for securing the channel member to the studding also acts as a plaster gauge, and in this form of construction the driven element 45 is shown as provided with an enlarged head 46 which in and of itself constitutes a plaster gauge.

In assembling wall or ceiling structures in which the channel members are secured to the frame members by driven headed elements, a channel member is first nailed to the frame member, whereupon a plaster board is put in position with one of its longitudinal edges engaged ina channel of the channel member. Thereupon another channel member is engaged with the opposite edge of the plaster board and this channel member is then secured to the frame member. This operation is continued until the wall or ceiling is completed.

In every instance where the longitudinal edges of the plaster boards are engaged and supported by the double channel members, which in turn are secured to the frame members, the other or adjacent end edges of adjacent plaster boards may also be reinforced by lengths of double channel members which extend between the lengthsof channel bars secured to the frame members. In

this manner all weaving and relative displaceence thereto, that any of the heretofore described forms of channel members may be utilized not withstanding the fact that the form of channel member illustrated in Figure 7 has been shownin Figure 25.

In Figure 25 the frame member is in theform of a metal channel member ll and the channel members it are secured thereto by attaching clips 48. While the illustration in Figure 25 is of a ceiling construction, it will be obvious that the same arrangement and organization of parts may be employed in connection with walls, in which event the frame members All would extend vertically instead of horizontally. When metal frame members All are employed in a ceiling construction they may be supported by suspension elements ll. As seen in Figure 32, these suspension elements can be connected to nails or the like li" driven into the wooden frame members i ll. In this manner any shrinkage of the woodenframe members til which generally causes a distortion thereof at their lower edges, will not result in a cracking of the ceiling structure.

The form of clip illustrated in Figures25, 26 and 2'7 consists of a channel portion 59 and a right angularly extending flange 523 with an open sided slot i, thus providing a pair of opposed jaws or lugs 52. Attachment of the clip 48 to the frame member 4'! is accomplished in the manner suggested in Figure 27, wherein one of the jaws 52 is engaged over one of the side flanges of the frame member, the other jaw engaging the base of the frame member to prevent longitudinal movement of the clip. The duplicate opposed jaw members or lugs 52 provide means for attaching the clip so that the channel portion &9 thereof may exten in" either direction. N i

In assembling wall or ceiling structures in which the clips iii are employed, one of the clips is first engaged with the frame member, whereupon a channel member is engaged with the clip and then another clip is engaged with the other channel of the channel member and with the frame member, Thereupon theedgeof a plaster It will be obvious, however, without specific refer-.

board is inserted in the last mentioned clip and the adjacent channel of the channel member, and thereafter another clip is-engaged with the opposite edge of the plaster board and with the frame member. Thereafter another double channel member, clip and board are assembled with the frame, member and with one another in the manner just described and this sequence of operation is continued throughout the assembling of the entire ceiling or wall structure.

.In Figure 28 a slightly modified form of clip construction is illustrated. In this form of construction the clipcomprises a channel portion 53 and areturnbentflange portion 5 3, slotted as at 55 to provide the. opposed lugs or jaws for engagement with the frame member 41.

In Figure 29 the clip comprises a channel portion 56 and a flange portion 5i extending laterally therefrom in the same general plane as the adjacent side of the channel portion 55, but slightly offset therefrom so that by reason of the slotted portion 58 thereof it may be engaged with the frame member ll.

. In Figure 30 still another form of modified clip is illustrated, and in this form of construction the clip is substantially U-shaped, so as to straddle the frame member dh Each clip is formed with a pair of channel portions 59 and a vertically extending portion 50, the vertically extendingportion being connected by a horizontal portion or flange 6!. so that each clip may straddle the frame member 47 and rest upon the upper flange thereof.

Inall ofthe forms of clips herein illustrated the frame engaging portions thereof may be reinforced or. otherwise strengthened by means-of ribs 62 pressed therein. A section through the clip shown in Figure 29 is illustratedin Figure 31.

In Figure 33 another modified form of clip is illustrated. This clip is formed with a channel portion 86 and a flanged portion 8! from which the jaws or lugs 82 are struckup preferably by slitting the metal and displacing the portion between the slits upwardly to form the opposed attaching lugs or jaws.

In Figure 34 another modified form of clip is shown provided with a channel portion 83 and opposed lugsor jaws 3 lformed by slitting the flange 85 thereof from the edge portion inwardly and then bending the slitted portion angularly upwardly and then parallel to the flange 85 to form the opposed attaching lugs.

.In Figure 35 still another modified form of construction is shown which comprises a channel portion 86 and a flange portion 3 5 having a return bent edge portion 38. This forms a portion of double thickness and from this portion of double thickness the attaching lugs 39 are struck up. This provides a simple but eflicient means for reinforcing the attaching lugs.

In Figure 36 a modified; form of frame member 98 is illustrated, the frame member being bent toform longitudinally extending grooves 9!. In assembling the attaching clip with the frame mem ber 96, the lugs or jaws thereof are adapted to extend into, one of the grooves 9i to thus further insure that the clips will not become accidentally disengaged.

In Figure 37 a plaster board 32 is illustrated in plan View, and it will be noted that the surface thereof is ruled to provide a plurality of vertical and horizontally extending marks or lines 63. The purpose of these lines is to facilitate the cutting of the plaster boards when boards of smaller dimensions than the standard size boards are desired. By the use of these lines the points mat which the board must be out can be readily determined by the workman constructing the ceiling or Wall and the board cut to size rapidlyand accurately without necessitating accurate measurements and the subsequent marking of the board to indicate the lines of cut.

In Figures 38 and 39 there is illustrated the two parts Hit and-llil of the type of double channel member hereinbefore referred to. In this form of construction the infringing parts are united by punching the metal as indicated at I82 to provide a plurality of tongues I03 which are subsequently tightly bent back upon the adjacent Wall structure as illustrated best in Figure 38. The punching and folding back may be carried out by a rotary or stamping method.

In Figures and 41 still another method and means for uniting the two parts of the channel member hereinbefore referred to are illustrated.

In this form of construction the two parts I04 and lot are united by pairs of tongues which may be conveniently formed by forming members i [it and 18?, the forming member I06 being shaped to provide a transverse slit and pairs of longitudinally extending slits whereby pairs of tongues I08 are provided. Subsequently these tongues can be bent back upon the adjacent metal by i means of forming members I09 and I I0. I

In Figure 42 there is illustrated several of the vertically extending wooden spaced members ll illustrated in Figure 1. In practice the plaster boards iii are secured in place by the double channel members E E2 which are arranged in longitudinally spaced relation transversely of the frame members I 1. These double channel members receive and support and reinforce the adjacent edges of the plaster boards, as previously pointed out. In practice these double channel members are secured to wooden frame members by driven headed elementssuch as nails or the like, and in Figure 42 two such driven headed elements H3 are shown as passing through the double channel members at each point of intersection with a frame member. When the parts are secured in position the frame members are rigidly tied together and weaving or relative movement between adjacent frame members or between the frame members and the plaster board supporting members and the plaster boards themselves is prevented. Employment of two driven headed members at each point of intersection of the channel and frame members insures a further degree of elimination of any relative weaving movement. The reference character H4 indicates the plaster coat applied to the wall board and I I5 the finish or surface coat applied on top of the main plaster coat.

Each of the several forms of construction herein described contemplates the use of a double channel member extending the entire length of the boards to be supported and contemplates further an integral double channel construction. In this manner the adjacent edges of the plaster boards are accurately aligned and all independent movement or weaving of the boards at the edges thereof is prevented. Furthermore, the

1 use of an integral double channel member facilitates the construction of thewall or ceiling and enables the same to be constructed quickly so as to be commercially acceptable and practicable.

In accordance with the present invention the construction of the double channel members is such that they may be quickly and economically manufactured in large quantities. The association with each form of channel member of a plaster gauge means insures the application of a sufiicient amount of plaster to the finished wall to insure a commercially satisfactory job. Moreover, the numerous other features and details of construction of the various elements comprising parts of this invention are such as to render this invention of practical value in the art. While several forms of the invention have been described herein somewhat in detail, it will be readily apparent that many other changesand modifications may be resorted to, without departing from the spirit and scope of the invention.

and to this end reservation is made to make such changes as may come within the purview of the accompanying claims.

What I claim as my invention is:

1. In a structure of the character described, a channeled plaster board supporting element, and means formed in one of the legs of said element and intermediate the longitudinal edges thereof and constituting a plaster gauge.

2. Ina structure of the character described, a plaster board supporting element comprising a member having a channeled portion, one leg of said channeled portion extending beyond the longitudinal edge of the other leg of the channeled portion, and means in the extended portion of the said leg providing a plaster gauge.

.3. In a structure of the class described, a plaster board supporting element developed from a single strip of material bent to form opposed channeled portions, one leg of each channel being extended laterally beyond the other leg thereof, and means providing a plaster gauge in the extended portion of each leg.

4. In a self-supporting stud for composition boards, a metal channel member provided with portions adapted to embrace adjacent sides of said composition board, at least one of said portions being provided with plaster retaining loops, stretched from the metal.

, 5. A metal, self-supporting stud for supporting composition boards, comprising a base, flanges disposed opposite said base, said flanges and base affording between them, grooves adapted to support adjacent edges of said boards, and stretched, arcuate loops formed in the metal of said flanges adjacent said base for bonding to the plaster.

6. A reenforced stud for composition board, comprising a member I-shaped in cross section, having parallel flanges and a base section being provided with plaster retaining loops stretched from the metal.

'7. In a self-supporting metal stud for supporting the adjoining edges of composition boards, a base member extending between the edges of said boards, and means for embracing the edges of said boards, said embracing means including loops stretched from the metal, said loops serving to bond the plaster to the boards and prevent cracking of the plaster at the board joints.

GORDON R. WALPER. 

